Hardware Design Considerations For An Efficient Vacuum Cleaner Using A BLDC Motor

Application Report
SLVA654A June 2014 Revised July 2015
Hardware Design Considerations for an Efficient Vacuum

Cleaner Using a BLDC Motor
Nick Oborny
ABSTRACT
A vacuum cleaner is a device that uses an air pump to create a partial vacuum to suck up dirt and dust
particles from a given surface. Vacuum cleaners are used in homes as well as in industries and come with
a variety of power levels, small battery-operated hand-held devices, domestic central vacuum cleaners
and huge stationary industrial appliances. A universal motor is typically used as suction motor across
vacuum cleaners. The universal motor is a series DC-motor that is specially designed to operate on
alternating current (AC) as well as on direct current (DC). Universal motors have high starting torque,
operate at high speed, and are lightweight. Universal motors are also relatively easy to control. However,
because of the wear in commutator brushes this type of motor is not preferred for continuous use.
Because of commutation these motors are typically very noisy. The associated disadvantages of DC
motors are also applicable to universal motors because this type of motor is closer in concept to DC
motors than AC motors. Major OEMs (original equipment manufacturers) are considering alternative motor
types to overcome these disadvantages. This application note considers the use of a BLDC motor for
vacuum cleaner application with good performance benefits.
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13
14
Contents
Suction Principle ............................................................................................................. 3
Brushless DC Motors (BLDC) .............................................................................................. 4
2.1
Construction of BLDC Motors ..................................................................................... 4
2.2
Working of the BLDC Motor ....................................................................................... 5
Microcontrollers ............................................................................................................. 10
Gate Driver and MOSFETs ............................................................................................... 10
Isolation ...................................................................................................................... 10
Power Management (8 to 60-V DC Power Supply) .................................................................... 10
CAP and QEP interfaces .................................................................................................. 10
Enhanced Controller Area Network (eCAN) ............................................................................ 10
High-Resolution and Synchronized ADCs .............................................................................. 11
DRV8301 .................................................................................................................... 11
Feedback Stage ............................................................................................................ 12
11.1 Torque or Commutation Loop ................................................................................... 12
11.2 Speed Loop ........................................................................................................ 12
11.3 Position Loops ..................................................................................................... 12
Conclusion .................................................................................................................. 13
About the Author ........................................................................................................... 14
References .................................................................................................................. 14
Suction Principle ............................................................................................................. 3
Cross Section of BLDC Motor .............................................................................................. 4
Working of BLDC motor ..................................................................................................... 5
Energizing Sequence and Trapezoidal Waveforms ..................................................................... 6
Commutation Process ....................................................................................................... 7
Speed Versus Torque ....................................................................................................... 9
1
2
3
4
5
6
7
8
9
10
11
List of Figures

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Hardware Design Considerations for an Efficient Vacuum Cleaner Using a

BLDC Motor
Copyright 20142015, Texas Instruments Incorporated
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Current Versus Torque ...................................................................................................... 9
TI BLDC Driver Circuit ..................................................................................................... 11
Block Diagram of BLDC Motor Control .................................................................................. 12
10
Feedback Loops for Sensorless Control ................................................................................ 13

List of Tables
BLDC Motor Specifications ................................................................................................. 8
BLDC Motor Advantages ................................................................................................... 9
Performance Comparison Between BLDC and Universal Motor ..................................................... 13

BLDC Motor

Suction Principle
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Suction Principle
A motor is attached to a centrifugal fan with angled blades. As the fan blades turn, they force air forward
toward the exhaust port. When air particles are driven forward, the density of particles (and therefore the
air pressure) increases in front of the fan and decreases behind the fan. The pressure level in the area
behind the fan drops below the pressure level outside the vacuum cleaner (the ambient air pressure). This
creates suction, which is a partial vacuum, inside the vacuum cleaner. The ambient air pushes into the
vacuum cleaner through the intake port because the air pressure inside the vacuum cleaner is lower than
the pressure outside. As long as the fan is running and the passageway through the vacuum cleaner
remains open, there is a constant stream of air moving through the intake port and out of the exhaust port.
BLDC Motor
Low Pressure
Centrifugal Fan
High Pressure
Air Flow
Figure 1. Suction Principle

The suction motor load consideration is interesting. One or more fans are attached to the motor shaft and
are rotated at a very high speed. The air entering the fan near the hub is forced to spin with the fan as the
air passes through the fan. The load to the motor is the force required to overcome the inertia of the air as
it enters the fan and is spun. When the air flow through the motor is reduced by increasing the resistance
to the air flow, the load on the motor is actually reduced and the speed tends to fall. Therefore to increase
the suction the current drawn from the mains increases, and hence the motor speed increases. The effect
of this is to increase the suction created by the motor which helps to counteract the effect of the resistance
to the air flow. Restricting the air flow completely creates the maximum possible suction. This maximum
suction occurs when a sealed suction gauge is used. In essence, the maximum suction is greater than the
suction which is produced in the normal operating range of the motor. Air watts is an effort to rate the
output power of the vacuum cleaner instead of the input power drawn from the power source. ASTM
International defines the air watt as shown in Equation 1.
0.117354 F S
where
F is the rate of air flow in ft3/m

S is the vacuum in inches of water lift


BLDC Motor
(1)
Brushless DC Motors (BLDC)
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The brushless direct-current (BLDC) motor is configured like a DC motor turned inside out with the
permanent magnets on the rotor and the windings are on the stator. Because of the absence of brushes
the disadvantages are eliminated such as sparking, noise and lower efficiency. These motors are also
known as electronically commutated motors (ECMs or EC motors) and are synchronous motors that are
powered by a DC electric source through an integrated inverter, which produces an AC electric signal to
drive the motor; additional sensors and electronics control the inverter output. The commutation is
electronically controlled. Commutation time is provided by back electromotive force (EMF) measurements
of either position sensors or by windings.
The BLDC motor is the ideal choice for applications that require high reliability, high efficiency, and high
power-to-volume ratio. A BLDC motor is generally considered to be a high performance motor that is
capable of providing large amounts of torque over a vast speed range. A BLDC motor is highly reliable
because it does not have any brushes that wear out and require replacement. When operated in rated
conditions, the life expectancy of a BLDC motor is over 10 000 hours.
2.1
Construction of BLDC Motors

BLDC motors can be constructed in several different physical configurations. In the conventional (also
known as inrunner) configuration, the permanent magnets are part of the rotor. In the outrunner (or
external-rotor) configuration, the radial-relationship between the coils and magnets is reversed. The stator
coils in the outrunner configuration form the center core of the motor, while the permanent magnets spin
within an overhanging rotor which surrounds the core. For this application, the inrunner configuration was
selected. Figure 2 shows that the rotor is in the center with the permanent magnets and that the stator
contains the windings. The inrunner configuration has lower rotor inertia and more efficient heat
dissipation when compared to the outrunner model. The most common BLDC motor topology uses a
stator structure consisting of three phases. As a result, a standard six-transistor inverter or six-mosfet
inverter is the most commonly used power stage.
Rotor with
Permanent
Magnets
Stator with
windings
Figure 2. Cross Section of BLDC Motor

BLDC Motor

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2.2
Working of the BLDC Motor

The starting-current setup in the circuit through the stator windings sets up a magnetomotive force (mmf)
which is perpendicular to the main mmf set up by the permanent magnet. According to Flemings left-hand
rule, a force is experienced by the armature conductors. As the armature conductors are in the stator, a
reactive force develops a torque in the rotor. When this torque is more than the load torque and frictional
torque, the motor begins rotating. The process of removing current from one circuit and giving it to another
circuit is known as commutation. Commutation of the three-phase BLDC motor occurs by the connecting
the entire bar phases (A, B, and C) together and naming the connected bar phases a neutral point. Now
the same current is shared between different phases. For example, if phase A is given positive current,
then A will have negative current. The current then flows through the neutral node, enters phase B, and
then finally passes out through phase B to ground. As shown in Figure 3 the positive current in one phase
becomes the negative current in another phase and is reused. Therefore in every case there are two
phases that are contributing to positive torque and one phase contributing to zero torque. If the torque of
each commutation interval is combined, the total torque is a contribution of two torques from two phases
that are perfectly flat. Therefore the torque for the motor at every interval and at every instant is constant
and a single current produces twice the torque.
Torque = (4 N Blr) I
= kr I
Figure 3. Working of BLDC motor

The commutation process is implemented using a microcontroller. The rotor position must be known for
exact commutation. Two methods are used to find the rotor position: sensor control and the use of Hall
Effect sensors.
2.2.1
Types of Control
2.2.1.1
Sensor Control
Sensor control uses the Hall Effect arrangement at the back-end of the motor. Three Hall Effect sensors
are placed 120 degrees apart. These are digital Hall Effect sensors. The sensors detect the transition from
the north pole to the south pole of the rotor. The transition is given using binary numbers. There are
several disadvantages of Hall Effect sensors including:
The sensors are very expensive.
Sensing requires a magnetic disk.
Additional mechanical parts and wiring issues cause reliability problems.
Hall Effect sensors require an additional power supply.

BLDC Motor
2.2.1.2
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Sensorless Control
The disadvantages of Hall Effect sensors listed in Section 2.2.1.1 are compensated for by using
sensorless control. One of the ways of overcoming the disadvantages of Hall Effect sensors is by using
back-EMF sensing. This method works because one coil is always de-energized according to the working
principle. The rotor position is then detected using the back-EMF signature of that coil. This signature is
the Zero crossing of that back-EMF signal.
The BLDC motor is a permanent magnet motor with a trapezoidal back-EMF, as opposed to the sinusoidal
back-EMF found in a permanent-magnet synchronous motor. Figure 4 shows the trapezoidal waveforms
of a three-phase BLDC. In every commutation step, one phase winding is connected to a positive supply
voltage, one phase winding is connected to a negative supply voltage, and one phase is floating. The
back-EMF in the floating phase results in a zero crossing when the phase voltage crosses the average of
the positive supply voltage and negative supply voltage. The zero crossings are indicated by ZC. The zero
crossing occurs directly in the middle of two commutations. At a constant speed, or a slowly varying
speed, the time period from one commutation to zero-crossing and the time period from zero-crossing to
the next commutation are equal which is used as basis for the implementation of sensorless-commutation
control. The floating phase, where the zero crossing must be detected, changes for every commutation
step. One ADC channel for each phase winding is needed to detect zero crossings.
The sensorless commutation method does not work during startup or at very low speeds. A simple-blind
start-up is used. A table of inter-commutation delays for the first few commutations is stored in flash. This
sequence is executed without attention to the back-EMF feedback. The control is then passed over to the
sensorless commutation controller.
P1
P2
P3
P4
P5
P6
A
ZC
ZC
A
State 0
Back-EMF (V)
IAB
IAC
State 1
B
ZC
ZC
B
ZC
ZC
ICB
State 2
IBC
State 5
Activation Voltage (V)
IBA
4
ICA
State 4
C
State 3
B
Figure 4. Energizing Sequence and Trapezoidal Waveforms

BLDC Motor

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2.2.1.2.1
Sensorless Control: Using Zero Crossing of the Back EMF Signal
Rotor-position detection occurs by using one of the two previously-mentioned methods. Figure 5 shows
the process of commutation. The 3-phase BLDC motor has been split into 12 stator poles as shown in
Figure 5. Phase winding occurs such that a positive current creates a south pole at A and A will then have
a north pole. Similarly C has a north pole and then C will have a south pole. Commutation can begin when
the rotor position is determined. When the rotor begins to move the south pole of the rotor enters the
region of the stator where the north pole exists. The sensor detects this movement, and before the rotor
can reach the north pole (region under the phase A), phase A is turned off because the rotor has entered
a new commutation zone. Phase B then turns on. The magnetic pattern on the stator is advanced by 300.
The rotor must move further in order to reach the north pole as shown in Figure 5(2). As the rotor travels
toward the north pole, it crosses a new commutation zone and the process continues on. There are six
stator commutation states and depending on the rotor position, the respective commutation state can be
applied.
Figure 5. Commutation Process
2.2.1.3
Calculations
Use Equation 2 to calculate the no-load speed.

No-load speed = V / KE 1000 (RPM)
where
KE = back-EMF constant (V/kRPM)
(2)
The KE constant can also be used to determine how fast a motor will run with a certain voltage applied to
it. The higher the applied voltage for a motor with a given back EMF constant (KE), the faster the motor
will run. Conversely the lower the applied voltage for a motor with a given back EMF constant (KE), the
slower the motor will run.
To calculate the voltage required at the motor, use Equation 3.
Voltage at motor (V) = ([L + M] / K [R]) + (KE w)
where
L = load torque (oz-in)

M = friction torque of motor (oz-in)
K = Torque Constant (oz-in/A)
KE = back EMF constant (V/kRPM)
R = Thermal resistance ()
w = desired motor speed (kRPM)
Torque () = K Current (I)


BLDC Motor
(3)
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Use Equation 4 to calculate efficiency.

= PO / PI
where
PO is the output power (see Equation 5)
PI is the input power (see Equation 6)
PO =
(4)
where
= angular velocity (rad/s)
= torque (Nm)
PI = rated voltage rated current
(5)
(6)
Table 1 lists the specifications of the selected motor (part number DN4261-24-053).
Table 1. BLDC Motor Specifications
VALUE
Rated speed
4000 RPM
KE
3.72 V/kRPM
5.027 oz-in/A
Rated torque
0.125 Nm = 17.7 oz-in
Weight
0.45 Kg
Body length
61 mm
Number of phases
Number of poles
To find voltage required at motor for different torques use Equation 7.

Voltage at motor (V) = ([(L + M) / K] R) + (KE w)
where
R = 2.6
L neglects M
(7)
Calculate the voltage to produce a torque of 15 oz-in at 3000 RPM using Equation 8.
V = ([15 / 5.027] 2.6) + (3.72 3) = 18.91 V
(8)
Use Equation 9 to find the voltage used to produce a torque of 15 oz-in at 4000 RPM.
V = ([15 / 5.027] 2.6) + (3.72 4) = 22.63 V
(9)
These equations can be used to calculate a similar voltage requirement for any given torque and speed.
The curve in Figure 6 is linear which provides better speed controllability.
As shown in Figure 7 the rated current of the motor is 3.54 A. The characteristic is linear.

BLDC Motor

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5.65129
4.95129
Speed (kRPM)
4.25129
3.55129
2.85129
2.15129
1.45129
13
17
21
25
29
33
37
Torque (oz-in)
Figure 6. Speed Versus Torque
22.52
7
20.027
Torque (oz-in)
17.527
15.027
12.527
10.027
7.527
1.4
1.6
2.2
2.6
3.4
3.8
4.2
4.6
Current (A)
Figure 7. Current Versus Torque

Table 2. BLDC Motor Advantages
BLDC ADVANTAGE
REASON
Linear speed-torque characteristics, better

controllability
Internal feedback. Permanent magnet design with feedback gives BLDC motors
linear characteristics when compared to open-loop AC-induction motors or brush DC
motors. Series DC motors have exponentially decreasing characteristics.
High starting torque
Internal feedback gives higher starting torque. The torque produced at any instant in
a BLDC will be twice the torque produced in brush DC motor of the same rating, as
two phases will be on in every commutation step.
Adjustable speed
With the Texas Instruments DRV8301 motor driver, smooth speed control is
possible.
Higher efficiency
A permanent magnet in the rotor reduces efficiency loss and increases the efficiency
by about 10%.
Better heat removal
The heat generated in the stator is dissipated easily as it is outside of the rotor
unlike the brush DC motor.
Noiseless
Because of the absence of brushes the operation is noiseless.


BLDC Motor
Microcontrollers
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Microcontrollers
TI's C2000 microcontroller (MCU) family can control BLDC motors using either scalar or vector-control
techniques. The rotor position can also be estimated using back EMF voltage information. This mode of
feedback control eliminates the need for sensors and additional wires. The position of the speed
estimators can also be used to calculate rotor position. Integrated high-speed 12-bit ADC converters, highresolution pulse-width modulators (PWMs) and a quadrature encoder input (QEI) on the C2000 MCUs
make them ideal for implementing BLDC motor control. The ability of the C2000 MCU core to execute
complex mathematical functions in a short time makes this family of MCUs ideal for implementing vectorcontrol techniques and controlling multiple motors at the same time. The PWMs in this family have
programmable dead band delays to drive high- and low-side gate drivers. The hardware-based faultdetection systems shut down systems faster without intervention from the software. The MSP430 MCU
devices are based on a 16-bit RISC architecture with ultra-low-power operation in active mode and sleep
mode.
Gate Driver and MOSFETs

Power amplifiers accept a low-power input from a controller IC and produce the appropriate high-current
gate drive for a power MOSFET. A gate driver is used when a PWM controller cannot provide the output
current required for driving the gate capacitance of the associated MOSFET. The gate driver turns the
MOSFET on and off. Motor drivers can be constructed from discrete components, completely integrated
inside an IC, or can employ both discrete and integrated components. TI has a wide range of discrete gate
drivers such as the UCC27210, UCC27200, TPS28225, and UCD7201 device for this purpose. External
MOSFETs such as the CSD88539, CSD88537, CSD18531, and CSD18533 device which are 60-V FETs
can be used with pre-drivers such as the DRV8301 and DRV8711 device. TI's DRV8312 and DRV8332
devices are pre-driver and FETs in an integrated package.
Isolation
Isolators have logic input and output buffers separated by a silicon-dioxide (SiO2) isolation barrier,
providing 4 kV of isolation. These devices block high voltages, isolate grounds, and prevent noise currents
from entering the local ground and interfering with or damaging sensitive circuitry. TIs ISO7420 and
ISO7140 series with 4-kV isolation and ISO7520 and ISO7641 series with 6-kV isolation specs are used in
this application report.
Power Management (8 to 60-V DC Power Supply)

A power-management block involves converting AC to DC and stepping down the DC levels as required
by the BLDC motor. TI has a wide range of high-voltage input DC-DC converters such as the TPS54060,
TPS54560, and TPS54361 devices that can be used in this application.
CAP and QEP interfaces

For motor-control systems based on sensors, integrating CAP and QEP sensor interfaces can both
simplify design and reduce cost. The sensor interfaces integrated into C2000 MCUs are built to work
across different types of sensors with built in 32-bit hardware for capturing an absolute time or a delta
time, in continuous or one-shot modes. This ability allows the interfaces to run independently in the
background without requiring constant management from the CPU.
Enhanced Controller Area Network (eCAN)

A controller area network (CAN) is used for serial communications between controllers in electrically noisy
environments. The eCAN interface on the C2000 MCUs provides efficient distributed real-time control with
data rates up to 1 Mbps, 32 fully-configurable mailboxes, 32-bit time-stamping, and programmable wakeup for low-power operation.
10

BLDC Motor

High-Resolution and Synchronized ADCs
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High-Resolution and Synchronized ADCs

The precision of sensorless systems is directly dependent upon accurate current measurements. Accurate
current measurements require not only an accurate reading (for example, resolution) but that the reading
must occur at a specific time. Advanced control techniques often have a short window that a feedback
sample must be acquired. As a result, precise timing has two parts: the ADC must be closely
synchronized to PWM events and samples must be aquired quickly.
10
DRV8301
TI's DRV8301 device is a three-phase driver with dual current-shunt amplifiers and a buck regulator. The
DRV8301 device includes two current-shunt amplifiers for accurate current measurement. The operating
supply voltage of the device is 8 to 60 V and can support up to a 200k-Hz switching frequency.
C2000
Controller
DRV8301
Push
Buttons
Inverter
Stage
DC
Supply
(8 V to
60 V)
Motor Connections
Figure 8. TI BLDC Driver Circuit


BLDC Motor
11
Feedback Stage
11
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Feedback Stage
Figure 9 shows the functional block diagram of the motor control. The following sections list the three
feedback loops involved.
ISO
Wired
Interfaces
Analog Feedback
ADC
Gate Drivers
ISO
Motor
Microcontroller
Encoder
Sensorless (B-EMF)
ADC
Plug
DC Bus
Rectifier
AC
Line
Figure 9. Block Diagram of BLDC Motor Control
11.1 Torque or Commutation Loop

The torque loop is used for sensorless applications to controll the current through the motor. The torque is
related to the current and therefore this feedback measures the current. A sense resistor measures the
voltage and current sense amplifier senses the current and sends the signal to the ADC which digitizes
the current and sends it to the controller. Measuring the motor current is often used as a safety feature. In
case the motor is in a stalled position, the current will increase dramatically. Because of this exceptional
increase in current, the ADC values will reach a current-limit level that will cause the system to shut down.
11.2 Speed Loop

This feedback involves optical encoder. An optical encoder is a device that converts motion into a
sequence of digital pulses. The output of the optical encoder is digital and there is no need for ADC.
11.3 Position Loops

A resolver or optical encoder can be used. If a resolver is used then an ADC must be used. An optical
encoder provides a digital output which eliminates the need for an ADC. The position loop is the backEMF signal feedback loop, which is required for commutation.
12

BLDC Motor

Conclusion
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3
Back-EMF signal
ADC
System
Controller
PWM
Controller
Gate Driver
H-Bridge
BLDC
Sense
resistor
ADC
Current-sense
amplifier
Optical encoder
Figure 10. Feedback Loops for Sensorless Control
12
Conclusion
Table 3 lists the performance comparison between a universal AC motor and a BLDC moto. The
comparison in Table 3 shows that the BLDC motor provides twice the efficiency gain with better control,
no noise, and lighter weight.
Table 3. Performance Comparison Between BLDC and Universal Motor
Power
Efficiency Noise
Size and Weight
AC MOTOR
BLDC MOTOR
150 W
35% hum
50 W
90% complete silence
The AC motor is bigger in size and 33% to 50% heavier than BLDC mortors
Limited to AC frequency (50 to 60 Hz) and is nonadjustable
Stepless control and auto adjustment by

working temperate
Temperature Rise
95C
40C to 45C because of higher efficiency
Application Range
Single purpose
Muli-purpose
Short
Long
Rotation speed
Life Span


BLDC Motor
13
About the Author
13
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About the Author

The author would like to thank the former electrical engineering students of M.S. Ramaiah Institute of
Technology (MSRIT) including Varun Nandakumar, Rajath Raghavendra, and Chandana P for fabricating
the BLDC motor to be mounted on the vacuum cleaner and testing the application as part of their finalyear bachelor's of engineering (BE) project.
14
References
1. Texas Instruments Motor Drive and Control website, www.ti.com/motor
2. Permanent Magnet Synchronous and Brushless DC motors (Ramu, 2009)
3. Speed Regulation of a Small BLDC Motor using Genetic-Based Proportional Control (Poonsawat and
Kulworawanichpong, 2008)
4. Simplified Sensorless Control for BLDC Motor, Using DSP Technology (Dixon, Rodriguez, and Huerta)
14

BLDC Motor

Revision History
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Revision History
Changes from Original (June 2014) to A Revision ......................................................................................................... Page
Changed the placement fo the Hall Effector sensors from 1200 degrees to 120 degrees in the Sensor Control section
..
NOTE: Page numbers for previous revisions may differ from page numbers in the current version.

Revision History
15
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Hardware Design Considerations For An Efficient Vacuum Cleaner Using A BLDC Motor

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Hardware Design Considerations For An Efficient Vacuum Cleaner Using A BLDC Motor

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Application Report

SLVA654A June 2014 Revised July 2015